THE DG 300 MARK 2 5-SPEEDTRANSAXLE GEARBOX UNIT

The Mark 2 DG300 Gearbox has five forwardratios and reverse. It is designed for usewith rear engine competition cars having acapacity of up to 4% litres.

Only one final drive ratio is used. Since thedrive is indirect at all times, any change inratio can be made through the gearbox. Thedrive is taken from the clutch shaft to thespiral bevel final drive via straight cutgears. Gear change is effected by non-syn-chronised face dogs. Ratios can be changedwithout removing the unit from the chassis,and all requirements can be met from ourextensive range of gears. All ratios exceptbottom are inter-changeable, and may bearranged in any order.

The differential and crown wheel assemblyis mounted on two taper roller bearingslocated in the side plates and adjustable tocorrect pre-load by shins. Output shafts arealso mounted in the side plates, and lip oil

seals are fitted.

The gears run directly on caged needle rollerbearings, and each gear and bearing revolvesas an assembly. Heat treated nickle-chromesteel is used for all gears and shafts. Selec-tor forks are cast in aluminium bronze, and

casings in magnesium alloy.

The differential is of Limited Slip design,the unit normally supplied being the Camand Paw1 type.

The gearbox unit is lubricated by oil splash,and the final drive by pump. The pump islocated in the main case, and is fed via afilter which can be withdrawn from the out-side of the case. The oil is piped out of themain case on the righthand side and returnsvia external piping, thus providing for thefitting of an oil cooler. The latter is stronglyrecommended to ensure that oil temperaturedoes not exceed its maximum of

The gear change rod is mounted low down onthe right hand side. The clutch is operatedby steel. fork and push-rod - accepted as thesimplest and most reliable system, es-pecially with monocoque chassis. The push-rod is actuated from a slave cylinder mountedon the side of the main case.

The general configuration of the DG 300Mark 2 Series provides the maximum utilisa-tion of power allied to minimum weight forthe power required to be transmitted.

Technical Specification

Gear rod movement.225 either side ofneutral for forwardgears. forward for reverse

Gear rod rotates total.

2 4

3 5

Oil Filler

Oil

4.300i

0 of gear

Dimensions in inches

2

IndexBacklash, adjusting . . . . . . . . .Bearing Carrier (Main) . . . . . .

Bearing Carrier (Clutch Shaft . . .Bearings

Layshaft and pinion, frontLayshaft and pinion, tail

Clutch Rings . . . . . . . . . .Clutch Shaft . . . . . . . . .Crown Wheel . . . . . . . . .Crown Wheel & Pinion, setting up

Differential Unit, RemovalDifferential Unit, Dismantling

End Case . . . . . . . . . . . .

Filter . . . . . . . . . . . .

Gearbox Unit . . . . . . . . .Gear Ratios, changing . . . . . .

Hubs . . . . . . . . . . . .

Layshaft . . . . . . . . . . . .

General noteson maintenanceand overhaul

PAGE

15, 1659

9, 15559

13, 1515

913

5

13

55

5, 7

7

Only genuine Hewland spares should beused as replacements. These are manufac-tured in our own workshops to the finetolerances necessary, and rigorously inspect-ed and tested:

New nuts and gaskets should always beused on re-assembly.

Main case and Diff. Compartment

Oil, capacities and type . . .Oil pump . . . . . . . . .Oil Filter . . . . . . . . .

Pinion . . . - . . . . . .Plungers . . . . . . . . .pre-load, adjusting . . .

Reverse Idler Gear . . .

Seleetor Finger . . . . . .Selector Forks, removal . . .Selector Forks, setting upSelector heads . . . . . .Selector Rods . . . . . .Setting up +

PAGE

9. . . 3. . . 13, 18. . . 8, 13

. . . 9, 13, 15. . . 5. . . 15

. . . 9

. . . 5, 9

. . . 5

. . . 7

. . . 5, 7

. . . 5, 7

Crown Wheel & Pinion . . . 15Selector Forks . . . . . . 7

Side Plates, removal . . . . . . 9Side Plates, Dismantling . . . 13

Technical specification . . . . . . 2

When warming the outside of the case, keepthe blowlamp moving. Do not overheat. Testwith a spot of moisture, which will bounceoff when the case is hot enough.

When refilling with oil, put half the quantityinto each filler hole. Never put all the oil inone oil sump.

Weight

Oil Capacity

Type of Oil

DG 300 Mark 2

118 lbs

3% pints

S.A.E. 80 or 90

‘ f ; . . .

3

The Gearbox unit

REMOVING THE UNIT

END COVER

1.

2.

3.

4.

5.

Remove the eight 5 / 1 6 UNF Nyloc nuts andwashers from the end cover. Take off coverand gasket.

Remove the split pins from the castellatedpinion and layshaft nuts.

Push the heads of the two outside selectorrods, thus engaging the gears. This locks thegear box by engaging 2 gears.

Remove the pinion nut, (left hand thread) andslacken off the lay shaft nut, (conventionalright hand thread)

Now withdraw the two outside selector rods,to disengage the gears.

BEARING CARRIER

1.

2.

R e m o v e t h e t e n 5 / 1 6 U N F n u t s a n dwashers.

Using a plastic mallet, tap the bearing carrierand remove it from the main case, completewith lay-shaft assembly and gear train. Sup-port the gears, hubs and clutch rings withthe hand, as they come off the pinion.

The gearbox unit is now completely removed.

Replace in reverse order to above.

CHANGING GEAR RATIOS

When changing a gear ratio, take off the slack-

ened layshaft nut and remove the layshaft fromthe bearing carrier. Gears are exchanged in pairs- one from the layshaft and one from the pinionshaft . Each gear is etched with two sets ofnumbers. The first is the number of its ownteeth. The second is the number of teeth on itsmating gear.

It is essential that gears should be correctlypaired according to these numbers.

7.

8.

9.

STRIPPING THE GEAR TRAIN

1 .

2.

3.

Remove hubs, clutch rings and gears. Washand inspect for wear and cracks, giving part-icular attention to the clutch rings.

Examine forks for heavy or uneven wear, andtest for excessive play between forks andclutch rings.

If forks are not to be stripped, check thatnuts are tight and properly tabbed. Continuestripping.

Undo the three allen cap screws (36) andtake out the to

)Selector Rod Springs and

balls (35 & 34 . Then take out the threeSelector Rods, one at a time, followed by thebottom balls and springs.

Undo the 3/8 UNC allen ca screw (44) andpush out the locking slugs. ( 43)

Inspect pinion and layshaft tail bearings andrenew if necessary. To remove, warm upsurrounding area. N.B. In layshaft bearingcheck for wear on steel sleeve in layshaftbearing and renew if necessary.

Re-assemble in reverse order to above, subjectto the following:-

10. When replacing bottom balls and springs, setup to correct height. About one-third of theball should be exposed. Continue by insertinglocking slugs and selector rods, then topballs and springs.

l l .Any hub renewed should be ident ical inlength with the original. If replacing all hubs,or main bearing carrier, check that overall_ _- __ _

TO REMOVE SELECTOR FINGER HOUSING (5)

4. Remove selector finger housing by:-

(I) Remove bung, spring and plunger, (16,17, 18) from the selector fin er housingand withdraw selector finger. (38)

(2) Undo 5/16 UNC Allen cap screw

length of pinion assembly has not been alter-ed. Clearance is essential to avoid overheat-ing and seizure, but too much clearance willcause excessive wear.

(3) Undo 5/16 UNF Nyloc nut inside housing

5. Remove gasket from bearing carrier.

6. To remove forks, knock back ‘locking tabs(52) and undo nut (53). Remove all three setsand lift off forks (49, 50, 51). Setting up the selector forks - overleaf

5

GEARBOX PARTS LIST

ILLUS.No. DESCRIPTION

Not illus Gearbox Complete StdNot illus Gearbox Complete Alternator Drive

Al 5/16" UNF Nyloc NutA2 5/16" Flat WasherA3 End Cover

A 4 Gasket End Cover

A 5 Selector Finger HousingA 6 Gasket Selector F ingerA 7 Nut Layshaft

A 8 S p l i t P i n

A 9 Bearing LayshaftAI0 B u s h

Al I StudA l 2 Bearing CarrierA l 3 ScrewA l 4 SpringA I 5 Ba I IA l 6 PlungerA l 7 SpringA l 8 PlugA l 9 Thrust WasherA 2 0 SpacerA21 Layshaft Std

A21 Layshaft with Integral 1st GearA22 Reverse & First Sliding GearA23 Hub FrontA 2 4 Needle Bearings

A 2 5 Clutch Ring

QTY

I

I3030

II

II

I2

II

7II

III

III

II

III

52

PART NUMBER

DC300DG300AFT20I 3FT2027

DG204DG260

DG203DG261

DG236DG2302LG2343

LG2292FT2026DG202

FT203 1FT2034FT2033DG2030

FT2032FT2035DG2345

DG2346DG234

DG234A

DG23 IDG226DG226 IDG232

ILLUS.No. DESCRIPTION QTY PART NUMBER

A 2 6 Hub Centre I DG227A 2 7 Hub Rear I DG228A 2 8 Inner Track 5th Gear I DG229A 2 9 Thrust Washer I DG2294A 3 0 Stud I FT2025A31 Bearing 2 DG229 IA 3 2 Nut I DG230A 3 3 Spacer I DG203 IOA 3 4 Balls : Steel 6 FT202 IA 3 5 Spring 6 FT2022A 3 6 Screw 3 FT 2023A 3 7 Screw I FT203 I IA 3 8 Selector Finger I FT252A 3 9 Bush 5/8” 2 F R O 3 6A 4 0 ‘0’ Ring I FT2037A41 Plate I FT2038A 4 2 Screws- 4 FT2039A 4 3 Plungers 2 FT2024A 4 4 Screws I FT2028A 4 5 Selector Rod 1st & Reverse I DG246A 4 6 Selector Rod 2nd /3rd I DG247A 4 7 Selector Rod 4th/5th I DG248A 4 8 Adjusting Spacer 3 FT2463A 4 9 Selector Fork I St/Reverse I DG249A 5 0 Selector Fork 2nd/3rd I DG250A51 Selector Fork 4th/5th I FT25lA 5 2 Tab Washer 3 FT2461A53 Nut 3 FT2462

THE GEARBOX UNIT (continued)

SETTING UP THE SELECTOR FORKS

Extreme accuracy in setting up is imperative toensure that gears engage freely, and to avoiduneven or excessive wear. The use of a HewlandForksetting. Jig is strongly recommended. De-signed specifically for DG 300 it will save costlysettingup time and vastly reduce the possibilityof error. (Fig. 1)

Note that when two layshaft gears run to-gether, their chamfered sides must faceeach other. (See diagram A)

1. Warm the case and drop in the pinion tailbearing as described above.

2. Place the jig in a vice. Slide the hubs, withtop gear and thrust washer, on to the dummypinion.

3. Attach the bearing carrier to the jig, usingtemporary nuts.

4. Tighten the pinion nut. Then check for correctclearance on top gear. (.008” to .0l0")

5. Remove from jig. Fit selector forks to rods,with nuts and washers.

6. Build up the hubs, gears and clutch rings,and slide them back on to the setting jig.

7. Adjust the forks individually. Correct posi-tioning required that:-

(a) The clutch ring should be centred on itshub, between the two gears.

(b) The clutch ring should engage fully witheither gear.

(c) When fully engaged with either gear thereshould still be 0.005 clearance betweenthe gear and clutch-ring faces.

When satisfied with the set-up, continue asfollows:-

8. Tighten all three selector rods using newnuts and tabs, at the same time, make surethat the selector rod heads are correctlyaligned, and that there is clearance between

RE:MOVE FROM JIG

9. Warm up surrounding area and put in layshaftbearing. Build up the complete layshaftassembly with gears, spacers and thrustwasher. Replace in bearing carrier

lO.Put the complete set up back into the jig.Re-check all clearances. Test all movements.When satisfied, take from jig and boit IT ontothe gearbox, using a jointing compound.

ll.Tighten the nyloc nuts around the bearingcarrier. Replace nuts on pinion, layshaft andtighten using torque spanner. Put in splitpins.

Fig. 2. The Hewland Forksetting Jig12.Replace the selector finger housin

8and

selector finger, renewingl

gasket (6). ut innew gasket (4) and rep ace the end cover.

The correct torque is 115 ft.lbs for pinionnut, and 80 ft.lbs for layshaft nut.

The Main Case and Differential Compartment

Removal and replacement of units and assemblies

D I F F E R E N T I A L A N D D R I V E 4.

1 .

2.

3.

4.

Take off slave cylinder (31) complete withclutch push-rod, by removing the two boltsand washers. 5.

Take off the left-hand side plate, havingfirst removed the 5/16 UNF Nyloc nuts andwashers and 3/8 UNF Nyloc nuts of the 4 tiebars. Loosen with light blows from a plasticmallet.

6.

Remove the four 1/4" UNC allen cap screws(51). Slide out complete clutch shaft ass-embly.

Remove small circlip and oil pump drivergear (16). Remove second circlip and pressclutch shaft out of spigot housing.

Remove the large circlip (45), then the bearing and the oil seal (46 & 47)

Support the complete differential assemblv ona hammer shaft and lift it out of the maincase.

Re-assemble in reverse order to above, and also:-

7. Fit a new oil seal (47). Replace any wornparts, giving particular attention to the bear-ing.

Remove the right-hand side-plate.

Replace in reverse order to above. 8.

C L U T C H S H A F T9 .

1. Unhook the spring (38) from the clutch forkclevis pin, enabling the fork to swing free.

2. Slacken off the top and bottom swivel pins_ .(36) and slide the thrust ‘bearing (50) andbearing carrier (49) off the end of the clutch

PINION REMOVAL

When bolting the spigot to its housing, put asmear of locking fluid on the four allen capscrews and jointing compound on spigot face.

Check that the bearing carrier rotates freelyafter tightening down the two swivel pins (36)

shaft. -

3. Remove the clutch fork (37) after taking outthe split pin and clevis pin.

To remove the pinion proceed as follows:-

1. Remove the 6 1/4 UNC allen cap screws (9)and warm up the outside of the main case (1).

2. Remove the pinion and housing bearing carrier(10) complete, through the side plate.

3. Take out the Idler gear by removing the splitpins (26) and locking nut (25). Now slide offIdler spigot.

OIL PUMP

Remove the circlip that retains the driven gearand remove gear and woodruff key cap screwsand slide out pump unit. To dismantle pump, seepage 13.

LAYSHAFT B E A R I N G

The layshaft bearing is removed by warming theoutside of the case, having first taken out thecirclip. This bearing will be damaged by remov-al, and should NOT be disturbed unless it hasto be renewed.

Wash and inspect all parts. Wash out main caseto remove sludge. Ensure that no small metallicobjects or particles have been left in the case.

9

MAIN CASE AND DIFFERENTIAL PARTS LIST

ILLUS.

No,DESCRIPTION QTY PART NUMBER

Cl Maincase I DG20lc2 Oil Filler Plug 3 F-t-201 Ic 3 Banjo Union Complete 2 LG2262c 4 Pinion Spacer I DG2222C5 Circlip I LG2 2048C 6 Bearing Roller Type I DC2221 AC7 Shim I DG223IC 8 Plnion Bearing Ball Type I DG2221 BC 9 A Ian Cap Screw 6 FG2233Cl0 Housing I DG.223CII Crown Wheel & PinIon I I .38 ratio I DG22lCII Crown Wheel & Pinion 9.31 I DG22l ACl I Crown Wheel & Pinion 8.31 I DG221 BC l 2 Oil Pump Assembly I DG265C l 3 Screws 3 DG2651C l 4 Circlip Clutch Shaft I DG2651 0C l 5 Gear Oil Pump I DG2657C l 6 Gear clutch Shaft I DG2659Cl7 Circlip I DG2658Cl8 Circlrp I DG2342.C l 9 Bearing I DG234ic20 Reverse Idler Assembly I FT237C2l Reverse Idler Spigot I FT2373c22 Bearing I FT2372C23 Gear I FT2371C24 W a s h e r I FT2374C25 Nut I FT2375

ILLUS.

No.DESCRIPTION QTY PART NUMBER

C26 Split Pin I FT2378

C27 Stud IO FT20l4

C28 Oil Filter I LG266C29 Plug I LG2661c30 Screw I DG2376C3l Slave Cylinder I FT2582C32 Bolts 2 F T2583c33 Push Rod I LG258c 3 4 Nut I FT2581

c 3 5 Push Rod End I F R 5 9C36 Swivel Bolt 2 FT256c 3 7 Clutch Fork I DG254C38 Spring I LG2584c 3 9 W a s h e r s 2 - - -

c40 Fulcrum I FT255C4l W a s h e r I DG2551c42 C lev is Pin I DC257c43 Split Pin I DG257 I

c 4 4 Circllp I F R390c 4 5 Circlip I FT2441 0C46 Bearing I FT24412c 4 7 Oil Seal I FT2441 IC48 Spigots, Types to suit most competitive Engines. Price andc 4 9 Bearing Carrier. Ditto a v a i l a b i l i t y o r

application.c50 Thrust Bearing I FT2451 I

C5l Screws 3 FT24413C52 Clutch Shafts. Types to suit most competitive engines.

Price and availability on application.

1 0

See for drawingand instruction

1 1

Stripping the Sub-assemblies

DIFFERENTIAL

The following instructions apply to the Cam-andPaw1 type Differential DG 300 gearboxes.

1 .

2 .

3 .

4.

5 .

6.

Bend back the tabs (20), remove the bolts(21) and take off the crown wheel (19).

Remove in turn the outer housing (17), outercam track (16) and inner cam track (14).

Remove the eight plungers (pawls) (15) fromthe pIunger carrier (13).

Wash and examine for wear or damage, givingparticular attention to pawls, and profiles ofthe cam tracks. Make certain that:-

The splines of the inner cam track are to-wards the drive shaft (3), diagram (B).

New bolts and tabs are used for the crownwheel. Tighten with a torque spanner to 75ft.lbs Smear bolts with locking fluid.

N.B. On re-assembly use a good quality greaseto lubricate the inner cam track bearingsurfaces. We recommend the use of ‘Moly-slip’ grease for this purpose.

Re-assemble in reverse order to above.

F I N A L D R I V E

Left-band Side Plate

1. Remove the drive shaft circlip (22) and knockout the shaft (3).

2 .

3 .

Support the side plate on fire bricks and warmit, having first covered the oil seal (7) witha block of metal for protection. The outertrack of the differential bearing (11) and theshims (10) should now drop out.

Remove the large circlip (9) which retains theside plate bearing (8) and oil seal (7), sothat both can be withdrawn.

Right-hand Side Plate

Follow the same procedure as above.

Re-assemble in reverse order to above fittingnew oil seals if necessary.

O I L P U M P

This unit is extremely sturdy and simple indesign. It operates at far below its maximumrating and is unlikely to suffer serious wear. Toclean it and inspect gears and body for possiblescoring, remove the four allen. cap screws (19)and take off the pump cap (18).

When re-assembling, make sure that the drivingshaft (16) is nearest the flat side of the cap.

O I L F I L T E R

Remove filter plug (29) and filter (28) clean-Renew if required.

NOTES ON RE-ASSEMBLY TO THE MAIN CASE

Replace the units and sub-assemblies in thereverse order to which they were dismantled,with special attention to the following:-

1.

2 .

Slide the oil pump home, then push the splin-ed end of the shaft (16) through the drivengear (12). Take care to replace the woodruffkey (14) and circlip (10). Secure it from theback with the three allen cap screws (13 onmain assembly) using a smear of lockingfluid.

When replacing the filter bung (28), do notover-tighten or you may collapse the filter. Itshould be ‘just possible to turn the filter,using slight hand pressure.

TO REMOVE PINION FROM BEARING CARRIERASSEMBLY

1 .

2 .

Place the whole assembly under a hydraulicpress whilst still in position on the pinionand press off.

Remove the bearing and shims remove thecirclip (5). Support the carrier on blocks andknock out the shims and bearings from hous-ing (10) by pushing from the front. NOTEwhich bearing is removed first as one bearingis roller and other is ball type. Inspect andrenew if necessary.

1 3

Fitting a new Crown Wheel and pinion

The crown wheel and pinion are supplied as apair, precision matched and lapped. Each pair isindividually tested and passed as perfect beforeleaving the factory, and neither part should everbe replaced without the other.

Setting up can be done in the usual way, usingengineer’s blue. A faster and more positivemethod, however, is to use the new HewlandSetting Gauge. Procedure is as follows:-

S E T T I N G U P

USING THE HEWLAND SETTING GAUGE

Proceed as follows:-

1.

2.

3.

4.

5.

6.

7.

8.

Using dummy bearings (we can supplythese if required) make up bearing housingassembly. Inset circlip (5) into assemblyhousing.

Fig. 5. Pinion in Setting Gauge

e pinion tail by putting on thet h bearingcarrier complete with the pinion tail bearing.

Press the bearings into the housing and bymeans of a feeler gauge determine the clear-ance at the end of the housing.

TO CHECK PINION DEPTH

9. Put setting gauge in position in place of sideplate of main case, bolt across the face.

Add 0.002” above the feeler gauge reading toallow for slight pre-load on bearings.

Remove the circlip and top bearing, insertshims and replace bearing and circlip.

Insert s acer (4) onto pinion and slide on thebearing h ousing assembly.

Slide on hubs and tighten up pinion nut.

10. Using a feeler gauge, determine the clearancebetween the setting gauge and pinion. Thedistance between the pinion and the settingjig must agree with the figure marked on thenew pinion. This is adjusted by means of thepinion spacer (4).

Warm up the main case and insert the pinionassembly.

11. Remove the setting gauge from the main case.

12.Remove the pinion bearing carrier assembly.Assemble the new bearings with the shimsfrom the dummy bearings.

Replace the allen cap screws (9). Due to a 13.Press the bearing carrier assembly onto theslight “float” on the dummy bearings support pinion.

1 5

14. Warm up the main case. He-insert the pinionassembly. Smear the allen cap screws with‘Locktite” and tighten up.

TO ADJUST THE PRE-LOAD

1 .

2.

3.

Assemble differential unit, using the newcrown wheel and solid dummy bearings inplace of the two inner differential bearings(11). The thickness of the shims is criti.cal.If they have to be renewed make sure theyare replaced with shims of same thickness asthe originals.

Assemble the differential unit and side platesto the main case. Holt up, incIuding tie bars,to normal tension.

Now turn the pinion by hand to test the pre-load. Adjust by means of shims until satis-factory.

NOTE: Turn the pinion with hubs removed. Usingreasonable effort it should be possible to turn itby gripping the splines, but more effort will beneeded with dummy bearings than with real ones.Make sure there is some evidence of backlash.Absence of backlash will give a false impressionof pre-load.

TO ADJUST THE BACKLASH

For this oed dial

eration you will require a post-mount-i ncr.rcator with an extended probe (Fig 4).

1. Remove the solid dummy bearings from thedifferential unit and replace them with dummybearings. (Real bearings with increased toler-ances for easy substitution).

Continued on next page

Fitting new Crown Wheel and PinionContinued from previous page

2. Insert the probe of the dial indicator throughspigot housing until it touches one of theteeth of the crown wheel (Fig 4) Note thereading on the dial indicator. Turn pinion byhand to rotate crown wheel, and take at least12 readings. (14 readings are standard prac-tice in our own workshops). Minimum readingshould be .004”.

8. To increase or decrease backlash, changeshims from one side of the differential to theother. But remember that, once the pre-loadhas been set, you can use only the shims thatare already there. Continue to test untilsatisfactory.

RE.ASSEMBLE AS FOLLOWS:-

4. Press inner bearings onto differential ass-embly.

5. Warm up one side plate, insert oil seal, sideplate bearing and circlip.

6. Press the drive shaft into the side plate andretain with circlip.

7. Insert shim or shims, and outer bearing track.Place a heavy weight on bearing to flattenout shims.

8. Repeat for the other side plate. After cooling,assemble one side plate to the main case.

drive unit as described above.omplete the assembly of the differential and

BACK AXLE PARTS LIST

ILLUS.

NO.DESCRIPTION QTY PART NUMBER

61 7/16” Nyloc Nut 6 FT 21950 2 Bolt Drive Shaft 6 FT2192

B3 Drive Shaft L.H. or R.H. 2 DG21904 5/16” Nyloc Nut 31 FT 2013B5 5/ I 6" Washer 31 FT 2027B6 Side Plate I DG 20587 Oil Seal 2 LG 2054B8 Bearing 2 LG 2053B 9 Circlip 2 LG 2052BIO Shim Sideplate Various HD 2061BI I Bearing 2. DG 2051B12 Limited slip Diff. I DC 212813 Plunger Carrier I DC 214B14 inner Cam Track I LG 216B15 Plunger 8 LG217B16 Outer Cam Track I LG215B17 Outer Housing I DC 213B18 Sideplate I DG 206

B19 Crown Wheel & Pinion See Chart MainCase

B20 Tab Washer 5 FT 2212

B21 Crown Wheel Bolt I O FT 221 IB22 Circllp 2 LG 2191B23 Drive Shaft Bolt 8 LG 2193B24 Drive Shaft L.H. or R.H. 2 DG 218B25 Nyloc Nut 3/8" 8 FT 2196B26 Tie Bar 2 LG 262B27 Tie Bar 2 DC 262

N.B. If renewing the differential carrier bearings,make certain that the width of the dummy ings used for pre-load and backlash are the samewidth as the new bearings.

16

ALTERNATOR DRIVE AND PARTS LIST

8

Special crown wheel pinion mustbe used with alternator drive.

ILLUS.No.

DID2D 3D4D5D6D7D8D9

DESCRIPTION

Support PlugEnd CoverBearingClrclIpDrive ShaftPulleyBracketNutS c r e w s

QTY PARTNUMBER

DG 2044ADG 204 AF T 2041 AF T 2042 ADC 2045 AF T 2046 AF T 2049 AF T 2043 AF T 2047 A

1 7

OIL PUMP AND PARTS LIST

ILLUS.

No.

DIODIIDl2

Dl3Dl4

D15

Dl6Dl7

Dl8

Dl9

I DESCRIPTIONI

QTY

Circlip

Gear Clutch ShaftGear Oil PumpOil Pump AssemblyWoodruff key

Oil Pump Body

GearGear

Pump CoverScrews

IIIII

II

II4

PART NUMBER

D G 2658D C 2659

D C 2657D G 265D C 2656D C 2652

D C 2655DC 2654

D G 2653DC 2651 I

A PairSpare Ratios

Special Machined Bearing Carriers, Selector Finger Housing, Crown Wheel

and Pinion, MUST BE USED WITH ALTERNATOR DRIVE. I

ADAPTOR PLATES

A wide selection of adaptors are stocked prices and availability

on application.

MISCELLANEOUS

Hylomar, Anon setting jointing compound

Rubber Coupling 5 1/4 P.C.D.Gasco ML, Metal Locking SealantForgings suitable for making up drive shafts to match the 5% P.C.D.Rubber Coupling Part No. SK 28

Setting Jig Less Pinion and BearingDummy Bearings for setting C.W.P.Clutch Aligning Tool Specify Clutch

1 8